Transcript FLK Gasentnahme deutsch - MPIP

Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Solutions for the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 1
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications of gas analysis systems in Cement Plants
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 2
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
Gas analyzer equipment in cement works must be able to
withstand a very tough environment:

high gas temperature up to 1400 C

high dust concentration up to 2000 g/m3

high content of Alkalis, Sulfates and Chlorides

in addition, high level of mechanical stress and strain
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 3
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Conventional gas sampling systems with water cooling have a
number of serious weak points:
Kiln inlet
FLK sampling system

they block up easily because of the condensation that
forms due to the low operating temperature

lime deposits and corrosion with water as coolant

caking of material on the probe causes excessive
mechanical stress

High cost for maintenance and low reliability
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 4
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
The problems with the gas analysis in cement rotary kilns can be
minimized or eliminated by using our patented gas sampling system
The Problem and our Solution
FLK sampling system
Gas flow

Formation of condensation
The operating temperature of 200 C at which our probe
operates is above the dew point of the flue-gas and the
acid.
Gas conditioning
Installation
Benefits

Lime deposits and corrosion with water as coolant
Using a special synthetic liquid as coolant prevents
lime deposits and corrosion
ROI
A&D PI2 SE1
Januar, 2003
Folie 5
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
The problems with the gas analysis in cement rotary kilns can be
minimized or eliminated by using our patented gas sampling system
The Problem and our Solution
FLK sampling system
Gas flow

Caking of material on the probe
Minor deposits are removed during regular automatic
retraction and cleaning with compressed air.
Gas conditioning
Installation

Benefits
High maintenance costs
Thanks to the high operating temperature and the
effective method of cleaning our system can achieve
periods of maintenance free operation up to three
months
ROI
A&D PI2 SE1
Januar, 2003
Folie 6
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
FLK Gas Sampling System
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 7
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Gas Sampling probe
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning

for gas temperatures up to 1400 C
Installation

gas sample temperature up to 200 C
Benefits

lateral intake chamber to reduce entry of dust
ROI

self-cleaning of dust deposits during retraction and insertion

variable probe length to meet the customer requirements

high mechanical stability due to oval design
A&D PI2 SE1
Januar, 2003
Folie 8
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Automatic Retraction unit
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation

in case of faults the probe is retracted automatically from the kiln

redundant motorized retraction due to electrical
and pneumatic motor

heavy duty and maintenance free mechanical design
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 9
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Dedusting Filter
Applications
Kiln inlet
FLK sampling system
Gas flow

electrically heated operation

operating temperature controlled
by thermostat

maintenance free sinter
metal filter

preheating of compressed air
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 10
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Purge unit
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI

automatical cleaning of gas paths

adjustable cleaning cycles

minimum pressure recognition
A&D PI2 SE1
Januar, 2003
Folie 11
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Heat exchanger
Applications
Kiln inlet
 synthetic coolant
 high boiling point
 environmentally friendly
FLK sampling system
Gas flow
 closed coolant circulation,
pressure free operation
Gas conditioning
 monitoring of temperature, flow
and level
Installation
 operating temperature
adjustabel (130C – 220 C)
Benefits
 fast and easy installation
and commissioning
ROI
A&D PI2 SE1
Januar, 2003
Folie 12
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Heat exchanger
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 13
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Control- and monitoring unit
Applications
 Compact cabinet
 with SIMATIC S7-300
or Allen Bradley SLC500
 central power distribution
Kiln inlet
FLK sampling system
Gas flow
 Function
 controlling of purge cycles
and gas sampling
 monitoring of temperature,
flow and level
 automatical probe
retraction in case of faults
Gas conditioning
Installation
Benefits
ROI
 easy to change parameter settings without programming expertise
A&D PI2 SE1
Januar, 2003
Folie 14
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Gasflow and cooling circuit
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 15
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Gas treatment and Analysis
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 16
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
Processoder
Analytics
Produktname
Gas treatment and Analysis
Applications
Kiln inlet
Up to 8 gas components in one analyser cabinet with the
Multi-Component gas analyser ULTRAMAT23
FLK sampling system

Up to 3 IR absorbable gas components plus oxygen
Gas flow

Easy-to-use menu driven operation
Gas conditioning

AUTOCAL with ambient air
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 17
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 18
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 19
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 20
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 21
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 22
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 23
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 24
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 25
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 26
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 27
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
A&D PI2 SE1
Januar, 2003
Folie 28
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
FLK Gas sampling system / Benefits

Synthetic heat transfer liquid instead of water

Gas sample temperature up to 200 C

no condensation-build up in the sampling probe
FLK sampling system

no lime deposits and corrosion
Gas flow

no freeze over of the coolant

high availability and less maintenance
compared with water cooled systems
Kiln inlet
Gas conditioning
Installation
Benefits

ROI
A&D PI2 SE1
Short commissioning time

the system comprise just 6 components

components ready to connect

typical commissiong time: 3 to 5 days
Januar, 2003
Folie 29
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Economic performance analysis of typical Customer benefits
Optimized burning process
 1% excess of Oxygen means:
10 kcal of extra energy consumption per kilo of clinker
 In the case of a kiln with a capacity of 3000 tons/day
operating 300 days a year, this means:
9.000.000.000 kcal of extra energy consumption per
annum
Benefits
or
ROI
1.097.560 kg of extra coal consumption assuming an energy
content of 8200 kcal per kilo of coal
A&D PI2 SE1
Januar, 2003
Folie 30
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Kiln inlet
Economic performance analysis of typical Customer benefits
Optimized burning process
With a coal price of $ 45 per ton this means:
FLK sampling system
Gas flow
Gas conditioning
 1.097,560 tons of extra coal x $ 45 = $ 49.365 higher energy
costs
 This saving means that the payback period on the investment
in FLK GAS is less than 2 years
Installation
Benefits
ROI
And remember too that this does not even take into account the
savings that can be made on maintenance compared with watercooled systems
A&D PI2 SE1
Januar, 2003
Folie 31
Process Instrumentation and Analytics
Siemens Process Analytics
in the Cement Industry
Bereichskennung
Process Analytics
oder Produktname
Applications
Economic performance analysis of typical Customer benefits
Optimized burning process
Kiln inlet
Investment
Saving
FLK sampling system
Gas flow
Installation
Benefits
ROI
USD
Gas conditioning
100
90
80
70
60
50
40
30
20
10
0
0
3
6
9
12
15
18
21
Months
A&D PI2 SE1
Januar, 2003
Folie 32
24